Hey Tom and the group,

Last December, I replaced the HVAC Recirculation Door in my '03 2500.  What
a royal pain.  See the thread at http://tinyurl.com/f4jm6 and you can see I
took out the screen to enable me to reach in and take out the door during
dissasembling so I didn't have to take out the entire dash and HVAC unit.

So, here it is 4 months later and I'm having the same 'low flow' issue
again, and of course I suspect the door.  I opened the glovebox and pulled
it off, reached up and through the back of where the glovebox sat and could
reach into the opening I left in the HVAC.  Sure enough, the door was
sitting on the bottom of the HVAC fan intake, blocking most of the flow.

I finagled around with one hand and one finger of another hand and pulled
the door out.  It was broken where the door driver's shaft goes in.  It
appears the driver tried to move the door further than the door could
possibly go, and split the plastic driven part of the door.

The door worked when I put it in.  The door worked for a few months.  There
is no adjustment.  To quote a bit of the book; "The heater-A/C control
module learns the recirculation air door stop positions during the
calibration procedure and will store a Diagnostic Trouble Code (DTC) for any
problems it detects in the recirculation door actuator circuits."

Any reason you can think of as to why my door broke a second time?  I do not
have any '3 key on/off' codes nor any dash codes.  Do I now need a DRBIII to
check the trouble codes or just drive without the door?  Help is
appreciated.

FMB